Installing Fuel Level Sensor

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Information

Replace seal for fuel level sensor.

Install fuel level sensor.
1. 1.1. Slide new seal on sensor.
2. 1.2. Insert fuel level sensor into the fuel tank.
  Make sure that the sensor mechanism has sufficient clearance.
3. 1.3. Connect electric plug connection.
  
  Fig 1: Connecting Plug Connection For Fuel Level Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.3.1. Join the two housing halves (yellow/blue) -2, 3- of the multiple plug connection.
  2. 1.3.2. Fit and engage the two-piece multiple plug connection on the fuel level sensor -1- .
4. 1.4. Connect the plug-in coupling for the fuel line -1- to the fuel level sensor.
  The plug-in coupling must lock with an audible click.
  
  Fig 2: Identifying Fuel Line On Fuel Level Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Insert the fuel level sensor and fit and tighten the metal catch.
  
  Fig 3: Inserting Fuel Level Sensor (RoW)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.5.1. RoW/USA variant: Place sensor in installation position.
    Installation is described for the RoW fuel level sensor. The procedure for the USA variant is the same.
Tighten the metal catch using special tool Lug Wrench P 9731 .

Fig 4: Identifying Special Tool (Lug Wrench P 9731)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Then tighten further until the notch -1- on the cap is between the white marking lugs -2- on the fuel tank flange.

Fig 5: Tightening Cap Position On Fuel Level Sensor
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Connect plug connections on the fuel level sensor.
1. 4.1. USA variant:
  
  Fig 6: Identifying Flange For Fuel Level Sensor (USA)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 4.1.1. Connect and lock the plug-in couplings for the fuel line -1- and vent line -2- .
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 4.1.2. Fit multiple plug connection -3- .
2. 4.2. RoW variant:
  
  Fig 7: Identifying Flange For Fuel Level Sensor (RoW)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 4.2.1. Connect and lock the rapid-action couplings for the fuel line -1- and vent line -2- .
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 4.2.2. Fit multiple plug connection -3- .